Concrete tube and formwork device and method for producing such a concrete tube

ABSTRACT

The invention relates to a method for producing a concrete tube (12) for a hyperloop passenger transport system. The concrete tube (12) is concreted in situ by means of a formwork device (10). The formwork device (10) has a formwork carriage (34) which moves forwards during concreting. The formwork carriage (34) has an inner form (20) and an outer form (22) for shuttering the concrete tube (12). An interspace (24) between the inner form (20) and outer form (22) is filled, in particular continuously, with concrete (32). The solidified concrete tube (12) can be supported on pillars (58a, 58b) via bearings. The freshly solidified portion of the concrete tube (12) is preferably supported on the inside by inner rollers (52a, 52b) and on the outside by outer rollers (54a). In order to support the formwork carriage (34) on the pillars (58a, 58b), the formwork device (10) can have supporting rollers (56a, 56b). The invention further relates to the formwork device (10) for implementing the method and to the concrete tube (12) produced by the method for the hyperloop passenger transport system

The invention relates to a formwork device for producing a concretetube. The invention also relates to a method for producing such aconcrete tube and to the concrete tube itself.

The production of horizontally installed concrete tubes is known. Forexample, EP 2 242 628 B1 discloses a method for producing concrete tubesfor sewers. The known concrete tubes have an expendable inner plasticstube and are manufactured in a trough. Once the concrete tube has set,it is removed from the trough and said trough is used again as a mold.

Furthermore, DE 1 784 718 C discloses a device for producing concretetubes. The known device uses a roller-compacting method for thispurpose.

It is also known to produce concrete tubes using what is known as aspun-concrete method. In this method, concrete is centrifuged against amold of a formwork device by means of a rotating roller.

Attempts are currently being made to construct a new kind of passengertransport system in which a passenger transport means, in particular inthe form of a train, is accommodated in an at least partially evacuatedtube. This passenger transport means is known by the name “hyperloop.”At a top speed of over 1000 km/h, this passenger transport means isintended to replace long-distance trains and short-haul flights in aparticularly energy-efficient manner.

One problem with this passenger transport system is, inter alia, thehigh construction costs for the tubes. Steel tubes suitable foraccommodating an above-mentioned passenger transport means costapproximately EUR 15,000 per running meter of tube.

The problem addressed by the present invention is therefore to provide atube suitable for accommodating a passenger transport means as describedat the outset that can be produced significantly more cost-effectively.

This problem is solved by a formwork device according to claim 1, amethod according to claim 12, and a concrete tube according to claim 15.The dependent claims set out expedient developments.

The problem according to the invention is thus solved by a formworkdevice for producing a horizontal concrete tube using a cast-in-placeconcrete construction.

According to the invention, “horizontal” is understood to meansubstantially horizontal, i.e. horizontal ±10°, in particular horizontal±5°.

Furthermore, a “cast-in-place concrete construction” is understood tomean setting the concrete on site, with the concrete structure obtainedafter it sets not needing to be transported any further.

The formwork device comprises a formwork carriage which can be movedforward during production of the concrete tube, in particular steadily.In the process, the concrete tube is produced by concrete beingintroduced into a space delimited by an inner mold, an outer mold, andan end element. The formwork device is open at the end opposite the endelement, such that the newly produced concrete tube remains stationary,while the formwork carriage is moved further forward and the concretetube continuously lengthens in the process. The formwork carriage can bemoved on spaced-apart columns, on which the concrete tube will later besupported. The concrete is introduced into the space through a fillingconnection.

The filling connection is preferably arranged such that the space can befilled from above. Particularly preferably, the filling connectioncomprises a filling funnel.

The space can be filled via a plurality of filling connections orpreferably via a single filling connection.

In a preferred embodiment of the formwork device, it comprises avibrator. The vibrator is preferably arranged in the region of thefilling connection.

Alternatively or additionally, the formwork device may comprise anagitator for homogeneously filling the space with concrete.

A critical parameter when pouring the concrete for the tubes is theconcrete setting as the formwork carriage slides along horizontally.This is because the concrete sets at a certain distance from the fillingconnection.

If the concrete is introduced into the space from above, for example,the solidification front of the concrete in the upper region of the tubeis horizontally further from the filling connection than in the lowerregion of the concrete tube: The lower part of the concrete tube is thenalready solidified, while the upper part is still soft and deformable.In order to make it possible to compensate for the differing progress ofthe solidification front in the horizontally upper and lower parts atleast in part, the end element is preferably oriented at an acute anglerelative to the horizontal. The acute angle is in particular between 47°and 67°, preferably between 52° and 62°.

The end element is preferably planar.

In order to make it possible to adjust the difference in distancebetween the solidification fronts, the angle of the end element relativeto the horizontal can be adjusted to a limited extent.

The inner mold is preferably designed for producing the concrete tubewith a minimum clear width of greater than 3 m, in particular of greaterthan 3.5 m.

The inner mold and the outer mold are preferably designed for producingthe concrete tube with a thickness of less than 20 cm, in particular ofless than 15 cm.

The concrete tube that can be produced by the formwork device can have apolygonal cross section, for example a square cross section. In order tomaximize the stability of a concrete tube of this type, however, itpreferably has an oval or circular inner circumference and an oval orcircular outer circumference. In order to produce a concrete tube ofthis type, the inner mold preferably has a cylindrical lateral outersurface, in particular a circular lateral outer surface, and the outermold has a cylindrical lateral inner surface, in particular a circularlateral inner surface.

The concrete tube is intended to be manufactured as precisely aspossible. For example, the diameter accuracy of the concrete tube shouldonly deviate from the desired diameter by a few millimeters. In order toachieve this, the formwork carriage preferably has an inner supportingstructure to which the inner mold is fastened and has an outersupporting structure to which the outer mold is fastened. The innersupporting structure and the outer supporting structure are preferablyrigidly interconnected, in particular fixedly and immovablyinterconnected.

The inner supporting structure and/or the outer supporting structure maycomprise a truss assembly. The truss assembly preferably comprises aplurality of steel struts.

More preferably, the outer supporting structure is arranged to beleading relative to the inner supporting structure. In this case, theouter supporting structure preferably extends by at least one columndistance in front of the filling connection.

In a particularly preferred embodiment of the invention, the innersupporting structure comprises an inner roller that can be supported onthe inside of the concrete tube produced using the formwork device. Theinner roller may be conical or spherical. Alternatively or additionally,the outer supporting structure may comprise an outer roller that can besupported on the outside of the concrete tube. As a result, the weightof the concrete tube can be reliably supported during the productionprocess without the concrete tube deforming. Preferably, the formworkdevice comprises a plurality of inner rollers and/or outer rollers forsupporting the concrete tube.

The formwork device may comprise a support roller, by means of which theformwork carriage can be supported on one of the columns. The supportroller may be rotatably arranged on the column or formwork carriage. Thesupport is preferably provided by a shoulder of the column. Preferably,a plurality of support rollers are provided for supporting the weight ofthe formwork carriage.

The inner roller, outer roller and/or support roller may have anexternal diameter of between 50 mm and 150 mm, in particular between 70mm and 130 mm, preferably between 90 mm and 110 mm.

The formwork device may comprise an outer support for supporting theouter mold. The outer support may be movable, in particular pivotable,in order to be able to pass by one of the columns when the formworkcarriage is moved. Here, the formwork device may be designed tohydraulically pivot the outer support.

Alternatively or additionally, the formwork device may comprise aconcrete tube support which supports the weight of the concrete tubeproduced after it has set. The concrete tube support may be movable, inparticular hydraulically, and in particular may be pivotable, in orderto be able to pass by one of the columns.

The formwork device may comprise a drive for moving the formworkcarriage forward when producing the concrete tube. The drive inparticular comprises an advancing hydraulic cylinder. The drivepreferably comprises a plurality of advancing hydraulic cylinders. Inthis case, the drive is more preferably designed for continuously movingthe formwork carriage forward.

In order to make it easier to slide the inner mold on the concrete tube,the formwork device may comprise a film between the concrete tube andthe inner mold. Alternatively or additionally, the formwork device maycomprise a film between the concrete tube and the outer mold in order tomake it easier to slide the outer mold on the concrete tube. The filmbetween the concrete tube and the inner mold may be inserted through aslot in the formwork device. Alternatively or additionally, the filmbetween the concrete tube and the outer mold may be inserted through aslot in the formwork device.

The formwork device may be designed to pivot, in particular rotate, theinner mold about the longitudinal axis of the inner mold. Alternativelyor additionally, the formwork device may be designed to pivot, inparticular rotate, the outer mold about the longitudinal axis of theouter mold. As a result, the concrete tube is prevented from adhering tothe inner mold and outer mold. Particularly preferably, the inner moldand the outer mold are pivotable, in particular rotatable, in oppositedirections in this case.

The formwork device may comprise at least one lubricating groove, inparticular a plurality of lubricating grooves, in order to make itpossible to introduce a lubricant between the concrete tube and theinner mold and/or the outer mold. As a result, the concrete tube isparticularly effectively prevented from adhering, in particular inconnection with the pivotable inner mold or outer mold.

The problem according to the invention is thus further solved by amethod for producing a horizontal concrete tube using a cast-in-placeconcrete construction in which concrete is introduced into the space inthe above-described formwork device in order to form the concrete tube.

The formwork carriage is moved forward to produce the concrete tube, inparticular at the same time as the space is being filled with concrete.

The formwork carriage is constantly, preferably continuously, movedhorizontally forward by more than 20 m, in particular by more than 100m, preferably by more than 1000 m, when pouring a concrete tube portion.

The advancing speed is preferably between 2 cm/min and 6 cm/min, inparticular between 3 cm/min and 5 cm/min. As a result, a good compromiseis reached between the quality of the concrete tube and a highproduction speed.

The problem addressed by the invention is further solved by a concretetube using a cast-in-place concrete construction for accommodating apassenger transport means, wherein the longitudinal axis of the concretetube extends horizontally, and the concrete tube has a seam-free lengthof greater than 20 m, in particular of greater than 200 m, and a minimumclear width of greater than 3 m. The concrete tube has preferably beenproduced using the previously described method.

The concrete tube preferably comprises ultra-high performance concrete(UHPC) having a tensile strength of greater than 150 N/mm². The concretetube may comprise between 0.5% and 2% steel fibers. The concrete tubepreferably has a preload force imparted by a plurality of stranded wiresthat are each over 100 kN.

All measurements stated relate to a uniform central portion of theconcrete tube, and not to the very first piece or the very end piece ofthe concrete tube.

Further features and advantages of the invention will become apparentfrom the following detailed description of an embodiment of theinvention, from the claims and with reference to the figures of thedrawings, which show details essential to the invention. The differentfeatures can be implemented in variants of the invention eitherindividually or in any combination. The features shown in the drawingsare set out such that the special features according to the inventioncan be made clearly visible.

In the drawings:

FIG. 1 is a schematic sectional view of a part of a formwork device whena concrete tube is being produced;

FIG. 2a is a complete side view of the formwork device from FIG. 1;

FIG. 2b is an enlarged partial view of the dashed region of the formworkdevice from FIG. 2 a;

FIG. 2c is a partial sectional view of the end face (from the left) ofthe formwork device from FIG. 2 a;

FIG. 2d is a view of the end face of the formwork device according toFIG. 2c , with the part of the formwork device for introducing theconcrete being positioned in the region of a column;

FIG. 2e is a partial sectional view of the end face of a part of theformwork device, with the part of the formwork device supporting thefinished concrete tube;

FIG. 2f is a view of the end face of part of the formwork deviceaccording to FIG. 2e in the region of a column; and

FIG. 2g is an enlarged partial view of the dashed region from FIG. 2 f.

FIG. 1 shows a formwork device 10 for producing a concrete tube 12 fromcast-in-place concrete. The concrete tube 12 has a fixed end 14 and afree end 16. The free end 16 is extended by formwork 18.

The formwork 18 has an inner mold 20 and an outer mold 22. The innermold 20 and the outer mold 22 define a space 24. The space 24 is closedat the free end 16 by an end element 26. The formwork 18 comprises,above the outer mold 22, a filling connection 28, in this casecomprising a filling funnel 30.

Concrete 32 is poured into the filling connection 28 and spreads outwithin the space 24. At the same time, a formwork carriage 34, whichcomprises the formwork 18, is moved away from the fixed end 14. As aresult, the set part of the concrete tube 12 is pulled out of the space24 and the concrete tube 12 is extended in the space 24 by freshlysetting concrete 32.

The formwork carriage 34 has a longitudinal axis 36 that extends in thehorizontal 38. Preferably, the longitudinal axis 36 of the formworkcarriage 34 is congruent with the longitudinal axis of the concrete tube12 or extends in parallel with the longitudinal axis of concrete tube12. When pouring concrete, the formwork carriage 34 is movedsubstantially in the direction of the extended longitudinal axis 36. Inthis case, bends in the concrete tube produced have a minimum radius ofgreater than 10,000 m, in particular of greater than 15,000 m,preferably of greater than 20,000 m.

The inner mold 20 and the outer mold 22 are set back in parallel withthe longitudinal axis 36 on the lower side of the formwork 18 oppositethe upper side of the formwork 18. The in particular planar end element26 has an angle of 0°<α<90° to the horizontal 38. As a result, thedifference in distance between the filling connection 28 and thesolidification front in the upper part of the space 24 or the lower partof the space 24 can be compensated for at least in part. In FIG. 1, forillustration, the upper and lower solidification fronts are indicated bythe signs E₁ and E₂. In order to make it possible to more effectivelycontrol the difference between the solidification fronts E₁, E₂ in theupper part of the concrete tube 12 and the lower part of the concretetube 12, the angle α of the end element 26 relative to the horizontal 38can be adjusted, as shown in FIG. 1 by a double-headed arrow 40. To dothis, the end element 26 may for example comprise a joint 42 at thelower end.

The inner mold 20 has a cylindrical lateral outer surface 44 and theouter mold 22 has a cylindrical lateral inner surface 46. The concretetube 12 produced therefore has an annular cross section.

The inner mold 20 is attached to an inner supporting structure 48, andthe outer mold 22 is attached to an outer supporting structure 50. Forreasons of clarity, the inner supporting structure 48 and the outersupporting structure 50 are dashed. The inner supporting structure 48supports the freshly produced concrete tube 12 on the inside by means ofinner rollers, of which the inner rollers 52 a, 52 b are shown in FIG. 1for reasons of clarity. The outer supporting structure 50 supports thefreshly produced concrete tube 12 on the outside by means of outerrollers, of which the outer roller 54 a is shown in FIG. 1 for reasonsof clarity.

The inner supporting structure 48 and the outer supporting structure 50are supported in the downward direction by support rollers, of which thesupport rollers 56 a, 56 b are shown in FIG. 1 resting on columns 58 a,58 b. The columns 58 a, 58 b are preferably cast in concrete and areshown FIG. 1 by dashed lines and significantly reduced in size forreasons of clarity.

At least one stranded wire for preloading the concrete tube 12 may bearranged at the fixed end of the concrete tube 12.

FIG. 1 shows, by way of example, a drive 60, which is in the form of anadvancing hydraulic cylinder that makes it possible to move the formworkcarriage 34 forward.

FIG. 2a is a side view of the formwork device 10. In this figure, theformwork carriage 34 extends over four columns 58 a, 58 b, 58 c, 58 d.The columns 58 a-d are between 5 m and 30 m tall, and spaced apart bybetween 10 m and 60 m, in particular between 30 m and 60 m. The innersupporting structure 48 and outer supporting structure 50 each extendover a length of greater than 50 m. The inner supporting structure 48trails by greater than 60% relative to a filling connection 28.

The outer supporting structure 50 leads by greater than 20%, inparticular greater than 30%, relative to the filling connection 28.

FIG. 2b shows a detail of the formwork device 10 from FIG. 2a in theregion of the filling connection 28. The upper cross section and thelower cross section of the concrete tube 12 can be seen in FIG. 2b . Theconcrete tube 12 is supported from the inside by inner rollers, of whichonly the inner rollers 52 a, 52 b are provided with a reference sign inFIG. 2b for reasons of clarity. A plurality of support rollers forsupporting the formwork carriage 34 are also visible in FIG. 2b , ofwhich only the support rollers 56 a, 56 b are provided with a referencesign in FIG. 2b for reasons of clarity.

FIG. 2c is a partial sectional end view of the formwork device 10together with the inner supporting structure 48, the outer supportingstructure 50 and the filling funnel 30. The inner supporting structure48 supports the inner mold 20 and the outer supporting structure 50supports the outer mold 22. The concrete tube 12 is visible between theinner mold 20 and the outer mold 22. From considering FIGS. 2a, 2b and2c together, it can be seen that both the inner supporting structure 48and the outer supporting structure 50 comprise a truss assembly. Thisensures high stability of the formwork device 10 with a relatively lowweight.

The outer supporting structure 50 may comprise at least one outersupport, in this case a plurality of outer supports 62 a, 62 b, forsupporting the outer mold 22.

FIG. 2d shows the formwork device 10 according to FIG. 2c in the regionof a column 58 a. As can be seen from considering FIGS. 2c and 2dtogether, the outer supports 62 a, 62 b would collide with the column 58a in the position according to FIG. 2c . In FIG. 2d , the outer supports62 a, 62 b are moved, in this case pivoted, out of the region ofmutually aligned columns 58 a-d (see FIG. 2a ). Here, the outer supports62 a, 62 b are each moved by a hydraulic drive 64 a, 64 b, which is notexplicitly shown in FIG. 2 d.

FIG. 2e shows the formwork device 10, which is positioned behind theinner mold 20 and the outer mold 22 (see FIG. 2c ) relative to theadvancing direction of the formwork device 10. In this case, theformwork device 10 comprises at least one concrete tube support, in thiscase two concrete tube supports 66 a, 66 b. The concrete tube support 66a and/or the concrete tube 66 b support may comprise an outer roller 54a, in order to support the concrete tube 12. In FIG. 2e , only the outerroller 54 a is visible. Preferably, the concrete tube supports 66 a, 66b alternately comprise an outer roller 54 a in the advancing direction.

According to FIG. 2e , the inner rollers 52 a, 52 b, 52 c, 52 d may bein the form of conical rollers or spherical rollers.

Similarly to FIG. 2d , FIG. 2f shows the position of a portion of theformwork device 10 in the region of a column 58 b. In order to prevent acollision with the column 58 b when the formwork carriage 34 movesforward, the concrete tube supports 66 a, 66 b are pivoted away.Hydraulic drives 64 c, 64 d, which are not explicitly shown in FIG. 2f ,are provided on the formwork carriage 34 for this purpose.

FIG. 2f also shows a bearing 68, which, in particular in the form of apoured concrete bearing, supports the concrete tube 12 on the column 58b. The bearing 68 is preferably produced after the portion of theconcrete tube 12 is produced in the region of the bearing 68.

FIG. 2g shows a detail from FIG. 2f . FIG. 2g shows, by way of example,the supporting of the formwork carriage 34, in this case the outersupporting structure 50, on an outer shoulder 70 of the column 58 b. Itis supported here by a support roller 56 a.

When considering all figures of the drawings together, the inventionrelates in summary to a method for producing a concrete tube 12 for ahyperloop passenger transport system. The concrete tube 12 is poured inplace by means of a formwork device 10. The formwork device 10 comprisesa formwork carriage 34, which moves forward while the concrete is beingpoured. The formwork carriage 34 has an inner mold 20 and an outer mold22 for forming the concrete tube 12. A space 24 between the inner mold20 and the outer mold 22 is filled with concrete 32, in particularcontinuously. The set concrete tube 12 can be supported on columns 58a-d by bearings 68. The freshly set portion of the concrete tube 12 ispreferably supported on the inside by inner rollers 52 a-d and on theoutside by outer rollers 54 a. The formwork device 10 may comprisesupport rollers 56 a, 56 b for supporting the formwork carriage 34 onthe columns 58 a-d. The invention further relates to the formwork device10 for carrying out the method and to the concrete tube 12 producedusing the method for the hyperloop passenger transport system.

1. Formwork device (10) for producing a horizontal concrete tube (12)using a cast-in-place concrete construction, wherein the formwork device(10) comprises a formwork carriage (34) that is horizontally movable onspaced-apart columns (58 a-d) and has an outer mold (22) and an innermold (20) that delimit a space (24), wherein concrete (32) is introducedinto the space (24) by means of a filling connection (28) to form theconcrete tube (12), and wherein the formwork device (10) comprises anend element (26) for closing the space (24) at the end.
 2. Formworkdevice according to claim 1, in which the filling connection (28), inparticular comprising a filling funnel (30), makes it possible to fillthe space (24) from above the inner mold (20).
 3. Formwork deviceaccording to claim 1 or 2, in which the angle (a) of the end element(26) can be adjusted relative to the horizontal (38) to a limitedextent.
 4. Formwork device according to any of the preceding claims, inwhich the inner mold (20) has a cylindrical lateral outer surface (44)and the outer mold (22) has a cylindrical lateral inner surface (46), inorder to produce the concrete tube (12) with an annular or oval crosssection.
 5. Formwork device according to any of the preceding claims, inwhich the formwork carriage (34) has an inner supporting structure (48)to which the inner mold (20) is fastened and has an outer supportingstructure (50) to which the outer mold (22) is fastened.
 6. Formworkdevice according to claim 5, in which the inner supporting structure(48) comprises a truss assembly and/or the outer supporting structure(50) comprises a truss assembly.
 7. Formwork device according to claim 5or 6, in which the inner supporting structure (48) comprises an innerroller (52 a-d) for being supported on the inside of the concrete tube(12) and/or the outer supporting structure (50) comprises an outerroller (56 a-b) for being supported on the outside of the concrete tube(12).
 8. Formwork device according to any of claims 5 to 7, in which theformwork device (10) comprises a support roller (56 a-b), by means ofwhich the formwork carriage (34) can be supported on one of the columns(58 a-d).
 9. Formwork device according to any of the preceding claims,in which the formwork device (10) comprises an outer support (62 a-b)for supporting the outer mold (22), the outer support (62 a-b) beingmovable, in particular hydraulically, in order to be able to pass by oneof the columns (58 a-d) when the formwork carriage (34) advanceshorizontally.
 10. Formwork device according to any of the precedingclaims, in which the formwork device (10) comprises a concrete tubesupport (66 a-b) for supporting the concrete tube (12), the concretetube support (66 a-b) being movable, in particular hydraulically, inorder to be able to pass by one of the columns (58 a-d).
 11. Formworkdevice according to any of the preceding claims, in which the formworkdevice (10) comprises a drive (60), in particular in the form of anadvancing hydraulic cylinder, in order to move the formwork carriage(34) horizontally forward when pouring concrete.
 12. Method forproducing a horizontal concrete tube (12) using a cast-in-place concreteconstruction by means of a formwork device (10) according to any of thepreceding claims, in which concrete (32) is introduced into the space(24) in order to form the concrete tube (12).
 13. Method according toclaim 12, in which the formwork carriage (34) is continuously movedhorizontally forward by more than 20 m when pouring a concrete tubeportion.
 14. Method according to claim 13, in which the advancing speedis between 2 cm/min and 6 cm/min, in particular between 3 cm/min and 5cm/min.
 15. Concrete tube (12) using a cast-in-place concreteconstruction for accommodating a passenger transport means, wherein thelongitudinal axis of the concrete tube (12) extends horizontally, andthe concrete tube (12) has a seam-free length of greater than 20 m, inparticular of greater than 200 m, and a minimum clear width of greaterthan 3 m.